Methods and systems for producing hydrogen

ABSTRACT

Exemplary embodiments of methods and systems for hydrogen production using an electro-activated material are provided. In some exemplary embodiments, carbon can be electro-activated and used in a chemical reaction with water and a fuel, such as aluminum, to generate hydrogen, where the by-products are electro-activated carbon, and aluminum oxide or aluminum hydroxide. Controlling the temperature of the reaction, and the amounts of aluminum and electro-activated carbon can provide hydrogen on demand at a desired rate of hydrogen generation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application relates to and claims priority from U.S. PatentApplication Ser. No. 61/511,322 filed Jul. 25, 2011, and U.S. PatentApplication Ser. No. 61/592,284 filed Jan. 30, 2012, the entiredisclosures of which are hereby incorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to exemplary embodiments of methods andsystems for producing hydrogen, and more particularly, to exemplaryembodiments of methods and systems for producing hydrogen from chemicalreactions.

BACKGROUND INFORMATION

Hydrogen can be considered to be a promising energy alternative tocarbon-based fuels. Various technologies have been developed regardingthe production and use of hydrogen as a fuel or energy source. Whilehydrogen may be considered to be a clean and desirable energyalternative to carbon-based fuels, various obstacles may exist inrelying on hydrogen as an energy source as opposed to other forms ofenergy. Such obstacles may generally include the ability to efficiently,safely and economically produce, transport and store hydrogen.

One approach to producing hydrogen can include thermochemical processes.One such process can include carrying out chemical reactions between asulfur-iodine compound and water at high temperatures (e.g., aboveapproximately 800 degrees C.). Generally, the process can result in thesplitting of the water molecules (H₂O) into hydrogen (H₂) and oxygen(O₂). The sulfur-iodine solution can be recycled in the process andtherefore, other than hydrogen and oxygen, there may be no harmfulbyproducts.

Another approach to producing hydrogen can include the electrolysis ofwater. Electrolysis requires the use of electricity, in accordance withFaraday's Law. Electrolysis can be a relatively inefficient process forproducing hydrogen without the aid of another energy source (beyond thesupply of electricity). Indeed, the energy consumed may be more valuablethan the hydrogen produced. In order to make electrolysis aneconomically viable process, another energy source can be incorporatedinto the process. For example, high-temperature electrolysis utilizes ahigh-temperature heat source to heat the water and effectively reducethe amount of electrical energy required to split the water moleculesinto hydrogen and oxygen with higher efficiencies. Another approach caninvolve the extraction of hydrogen from fossil fuels, such as naturalgas or methanol. This method can be complex and result in residues, suchas carbon dioxide. Also, there is a worldwide limit to the amount offossil fuel available for use in the future.

Other approaches are needed to address hydrogen production, such thatthe hydrogen production may be carried out in an effective, efficientand safe manner. A hydrogen-based economy can be a long-term,environmentally-benign energy alternative for sustainable growth. Anincreasing demand for hydrogen may arise as the worldwide need for moreelectricity increases, greenhouse gas emission controls tighten, andfossil fuel reserves wane.

SUMMARY OF EXEMPLARY EMBODIMENTS OF THE DISCLOSURE

At least some of the above described problems can be addressed byexemplary embodiments of the methods and systems according to thepresent disclosure. The present disclosure describes exemplaryembodiments of methods and systems that can produce hydrogen on demand(HOD), which can make it unnecessary to store hydrogen in a pressurizedtank.

The exemplary embodiments of the present disclosure describe methods andsystems that can make it possible to control and sustain the continuousproduction of hydrogen. The controlled, sustained production of hydrogencan be achieved by, e.g., providing a chemical reaction with water,aluminum and an electro-activated material (e.g., electro-activatedcarbon). This chemical reaction can produce hydrogen at variousproduction rates, and the hydrogen can be provided by, e.g., ahydrogen-production cell. The use of electro-activated carbon can makeit feasible to provide a high production rate for hydrogen for varioususes, such as but not limited to a fuel for, e.g., land vehicles, marinevessels and trans-oceanic ships, and also as a power source forcommercial power plants and other plants in remote locations.

The exemplary embodiments of the present disclosure further describemethods and systems which can provide for safe, on-board and on-demandproduction of hydrogen close to a user system, using simple, safe andpollution-free metal oxidation reacting with water and electro-activatedcarbon. The electro-activated carbon in the exemplary embodiments canprovide for a high-production rate, and a large-volume production ofhydrogen. It can also provide low flow rate for applications in whichsmaller fuel cells may be required, such as, e.g., cellular phones.

For example, according to one exemplary embodiment of the presentdisclosure, a method of producing a catalyst for hydrogen production canbe provided, comprising providing electrical energy to a carbon materialto electro-activate the carbon material, and using the electro-activatedcarbon material to produce hydrogen. The carbon material can be providedin a liquid composition comprising water, and the liquid composition canfurther comprise an electrolyte. The electrical energy can be providedat approximately 6 ampere-hours. The carbon material can be one or moreof pure carbon, solid carbon, crushed carbon, sintered carbon, carboncomposites, charcoal, pressed carbon, carbon blocks, graphite, carbongranules, granulated activated carbon or coal.

According to another exemplary embodiment of the present disclosure, amethod of producing hydrogen can be provided, comprising combiningelectro-activated carbon with a liquid composition, and generating achemical reaction between the combination of electro-activated carbonand the liquid composition to produce hydrogen. The method can furthercomprise combining the electro-activated carbon and liquid compositionwith a fuel, and generating a chemical reaction between the combinationof the electro-activated carbon, liquid composition and fuel to producehydrogen. The fuel can be pure aluminum, aluminum powder, aluminumgranules or aluminum shavings.

The method can further comprise controlling the chemical reaction of thecombination of electro-activated carbon, water and fuel to producehydrogen on demand. The chemical reaction can be controlled by heatingthe combination to increase the production of hydrogen, and by coolingthe combination to decrease the production of hydrogen. The combinationcan be heated to a temperature range between approximately 150 degreesFahrenheit to approximately 190 degrees Fahrenheit. The chemicalreaction can be controlled by adding amounts of one or more of theelectro-activated carbon, liquid composition and fuel to increase theproduction of hydrogen, and removing amounts of one or more of theelectro-activated carbon, liquid composition and fuel to decrease theproduction of hydrogen. The liquid composition can comprise water, tapwater, dirty water, high-calcium water, salt water, sea water, alkalinewater or acidic water.

According to another exemplary embodiment of the present disclosure, asystem for producing a catalyst for hydrogen production can be provided,comprising an activation cell having a carbon material, and an apparatusconfigured to provide electrical energy to electro-activate the carbonmaterial in the activation cell. The carbon material can be provided ina liquid composition comprising water in the activation cell, and theliquid composition can further comprise an electrolyte. The apparatuscan be configured to provide electrical energy at approximately 6ampere-hours. The carbon material can be one or more of pure carbon,solid carbon, crushed carbon, sintered carbon, carbon composites,charcoal, pressed carbon, carbon blocks, graphite, carbon granules,granulated activated carbon or coal.

According to another exemplary embodiment of the present disclosure, asystem for producing hydrogen can be provided, comprising a vesselhaving a liquid composition and electro-activated carbon, and anapparatus for generating a chemical reaction between the liquidcomposition and electro-activated carbon to produce hydrogen. The systemcan further comprise a fuel provided in the vessel with the liquidcomposition and electro-activated carbon, wherein the apparatusgenerates a chemical reaction between the liquid composition,electro-activated carbon and fuel to produce hydrogen. The fuel can beone of pure aluminum, aluminum powder, aluminum granules or aluminumshavings.

The system can further comprise one or more mechanisms to control thechemical reaction between the liquid composition, electro-activatedcarbon and fuel to produce hydrogen on demand. The one or moremechanisms can heat the combination of the liquid composition,electro-activated carbon and fuel to increase the production ofhydrogen, and can cool the combination of the liquid composition,electro-activated carbon and fuel to decrease the production ofhydrogen. The one or more mechanisms can heat the combination ofelectro-activated carbon, water and fuel to a temperature range betweenapproximately 150 degrees Fahrenheit to approximately 190 degreesFahrenheit. The chemical reaction can be controlled by adding amounts ofone or more of the electro-activated carbon, liquid composition and fuelto increase the production of hydrogen, and removing amounts of one ormore of the electro-activated carbon, liquid composition and fuel todecrease the production of hydrogen. The liquid composition can comprisewater, tap water, dirty water, high-calcium water, salt water, seawater, alkaline water or acidic water.

The exemplary embodiments of the methods and systems according to thepresent disclosure allow for hydrogen generation from a liquidcomposition such as water. Further, the by-products can potentially be apollution-free source of material for recycling to produce morealuminum.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects of the present disclosure will beapparent upon consideration of the following detailed description, takenin conjunction with the accompanying drawings and claims, in which likereference characters refer to like parts throughout, and in which:

FIG. 1 illustrates an activation cell used to prepare a catalyst thatcan be used to produce hydrogen according to exemplary embodiments ofthe present disclosure;

FIG. 2 illustrates a system for the production of hydrogen according toexemplary embodiments of the present disclosure;

FIG. 3 illustrates a system for the production of hydrogen according toexemplary embodiments of the present disclosure;

FIG. 4 illustrates a system for providing hydrogen as a fuel for avehicle according to exemplary embodiments of the present disclosure;and

FIG. 5 illustrates a boiler system according to exemplary embodiments ofthe present disclosure.

Throughout the figures, the same reference numerals and characters,unless otherwise stated, are used to denote like features, elements,components or portions of the illustrated embodiments. Moreover, whilethe present disclosure will now be described in detail with reference tothe figures, it is done so in connection with the illustrativeembodiments. It is intended that changes and modifications can be madeto the described embodiments without departing from the true scope andspirit of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF DISCLOSURE

Exemplary embodiments of the methods and systems according to thepresent disclosure will now be described, including reference to thefigures.

Initially, in an exemplary embodiment of the present disclosure, amethod and system for preparing a hydrogen producing catalyst isdescribed. FIG. 1 illustrates a diagram of an activation cell 100 usedto prepare a catalyst that can be used to produce hydrogen. In theexemplary embodiment of FIG. 1, the material can be carbon. The carboncan be any type of carbon of various forms, and the present disclosureis not limited to any particular form of carbon.

The activation cell 100 can have an anode 102 and a cathode 104. In anexemplary embodiment, the anode 102 can be placed inside the activationcell 100 along a first side 100 a of the activation cell 100, and thecathode 104 can be placed inside the activation cell 100 along a secondside 100 b of the activation cell 100. The anode 102 can be a metalanode and the cathode 104 can be a metal cathode, and any type of metalcan be used for the anode 102 and cathode 104, such as stainless steel,iron, galvanized iron, carbon and/or other metals, and the presentdisclosure is not limited to any type of metal. The metal can beelectrically conductive and resistant to corrosion.

A liquid composition can be provided in the activation cell 100, such aswater 108 or other liquid containing water, or other suitable liquidcomposition, and is not limited to water. The water 108 can be tapwater, filtered water, salt water, sea water and/or other types ofwater. A material such as carbon 106 can be provided in the water 108 inthe activation cell 100 in the form of, e.g., charcoal or graphite, sothat it can be electro-activated. The activation cell 100 can be open ona top surface to allow ventilation and the placement of the water 108and carbon 106. The water 108 can be in sufficient quantity to, e.g.,cover the material being electro-activated. The activation cell 100 canbe placed in a well-ventilated area such that any gas that is producedfrom the liquid during the electro-activation process can be ventilated.

An electrolyte can be placed into the activation cell 100 with the water108 and carbon 106, which can make the mixture of the water 108 andcarbon 106 more electrically conductive. Examples of electrolytes thatcan be used include, but are not limited to, sodium bicarbonate, sodiumchloride or potassium hydroxide. The electro-activation can also becarried out with no added electrolyte, and a higher voltage may be usedas the water can be less electrically conductive when an electrolyte isnot added to the water. Electrical energy can be passed through themixture of the water 108 and carbon 106 to electro-activate the carbon106. For example, electrical energy, such as in the form of electricalcurrent, can be passed through the mixture of water 108 and carbon 106until a value of approximately 6 Ampere-hours is achieved. Also, forexample, a range of voltage may be used, such as from approximately 4volts to approximately 200 volts. Typically, a voltage in the range ofapproximately 12 volts to approximately 150 volts can be used. Theexemplary embodiments of the present disclosure are not limited to anyAmpere-hours or voltage, and adjustments may be made based on variousfactors, such as but not limited to the amount of water, the amount ofmaterial (e.g., carbon), the size of the activation cell, and/or otherfactors including the current density (e.g., Amperes per squarecentimeter) which can be a function of the geometry of the cell.

The catalytic activation cell 100 can be designed to run at a lowcurrent, e.g., less than approximately 5 amps, and can run continuouslywith no overheating due to power dissipation in the catalytic activationcell 100. This can provide for electro-activation of the material (e.g.,carbon), and thereby convert the material into an electro-activatedmaterial. In the exemplary embodiments described above, carbon can beconverted into electro-activated carbon, which can be referred to ascatalytic carbon. Electro-activated carbon and catalytic carbon are usedinterchangeably in the present disclosure. Electro-activating the carbonat a low current can provide an advantage that the electro-activationmay not need to be monitored to intervene in the event of, e.g.,excessive current, excessive temperature or excessive gas emission fromthe cell.

In other exemplary embodiments of the present disclosure, the catalyticactivation cell 100 can be designed to run at higher energy levels, suchas 6 Ampere hours, which can be achieved by, e.g., providing electriccurrent for 6 hours at a current of 1 Ampere, or for 3 hours at acurrent of 2 Amperes. In various embodiments of the present disclosure,different times and currents can be used to achieve 6 Ampere hours. Thepresent disclosure is not limited to any particular Ampere-hours, andother Ampere-hour treatments would also produce catalytic transformationof the carbon.

The catalytic carbon (electro-activated carbon 106) can then be removedfrom the activation cell 100, and may be dried if desired. Once dried,the catalytic carbon may be easier to store and/or ship. The catalyticcarbon may be dried by, e.g., air drying, heating in air, and/or othertypes of heating/drying mechanisms and/or methods. Different dryingmethods/processes may be used, and temperatures from standard roomtemperature to up to 200 degrees Fahrenheit can be used, and are notlimited to such.

Exemplary Catalytic Reactions

In exemplary embodiments of the present disclosure, the chemicalreaction:

2Al+6[H₂O]+C=>C+2[Al(OH)₃]+3H₂   Equation (1)

can be used, where Al is aluminum, H is hydrogen, O is oxygen and C isthe electro-activated carbon (or catalytic carbon) formed by the processdescribed above. In this exemplary catalytic reaction, the aluminum andwater (H₂O) can be used as fuels with the catalytic carbon, and hydrogen(H₂) can be produced where the by-product is aluminum hydroxide(Al(OH)₃). In this exemplary reaction, water and aluminum are fuels thatcan be consumed, and the catalytic carbon C can be a catalyst. Otherliquid compositions having water, or having similar properties as water,can also be used.

The same reaction can be written as:

2Al+3[H₂O]+C=>C+Al₂O₃+3H₂   Equation (2)

where Al is aluminum, H is hydrogen, O is oxygen and C is theelectro-activated carbon (catalytic carbon) formed by the processdescribed above. In this exemplary chemical reaction, the aluminum andwater (H₂O) can be used as fuels with the catalytic carbon, and hydrogen(H₂) can be produced where the by-product is aluminum oxide (Al₂O₃).Aluminum hydroxide can reduce to aluminum oxide when dried, to removewater from the aluminum hydroxide. Because the hydrogen-producingreaction can be carried out in water, Equation 1 showing an aluminumhydroxide product is the reaction mostly used, while Equation 2 showingan aluminum oxide product can also be used when describing thechemistry. In this exemplary reaction, water and aluminum are fuels thatcan be consumed, and the catalytic carbon C can be a catalyst.

According to the exemplary embodiments of the present disclosure, manydifferent forms of carbon can be electro-activated as described above toproduce catalytic carbon. For example, in various experiments performedaccording to the exemplary embodiments of the present disclosure, it hasbeen shown that hydrogen can be produced using carbon in many forms,which can include but is not limited to, pure carbon, solid or crushedcarbon, sintered carbon, carbon composites, charcoal, pressed carbon(e.g., in the form of flat plates), carbon blocks (e.g., electric motorbrushes) that can be formed with chemical binders, graphite (e.g.,powdered carbon), carbon granules (e.g., for use as deodorizers),granulated activated carbon (GAC) that can be used for, e.g., waterpurification/filtering, and/or coal (lumped coal or crushed/pulverizedcoal).

Further, a fuel may not be required in order to generate hydrogen.Experiments have shown that catalytic carbon alone with a liquidcomposition, such as water or containing water, can produce hydrogen,according to the reaction:

H₂O+CC=>CC+H+OH   Equation (3)

A fuel can, however, increase the rate of production of hydrogen in thechemical reactions shown in Equations (1) and (2). When hydrogen atomsare generated, they can tend to combine, as in H+H=>H₂ (a gas), which isreferred to as the Toffel reaction. A competing reaction can also occur,such as H+OH=>H₂O, a “recombination” reaction that can prevent thehydrogen from being liberated in the form of H₂ gas.

A fuel, such as aluminum, can be provided to help in this reaction as OHgroups can be bound to the aluminum (Al) so that the accumulation offree (un-bound) OH groups can be largely prevented, such as in theliquid composition having the electro-activated carbon and aluminum, andthe recombination with hydrogen atoms to form H₂O can be prevented.

Other elements, chemicals or fuels having the same effect as aluminumcan also be used. For example, chemicals that tie up one OH group can behelpful, such as but not limited to Li (can form lithium hydroxide), Na(can form sodium hydroxide), K (can form potassium hydroxide), Rb (canform rubidium hydroxide) and Cs (can form cesium hydroxide). Otherchemicals can be more helpful, which can tie up two OH groups, such asbut not limited to Ca (can form calcium hydroxide), Sr (can formstrontium hydroxide) and Ba (can form barium hydroxide).

Exemplary embodiments of the present disclosure can provide for aluminumas the fuel as each atom of aluminum can tie up three OH groups tobecome aluminum hydroxide, Al[OH]₃, aluminum can be inexpensive andsafe, and aluminum can have a higher chemical binding energy than the OHgroups. Some chemicals can be even more helpful such as barium oxide(BaO), which can tie up as many as 4 or 5 OH groups. Some experimentshave shown that barium oxide can be a very good fuel with regard tohydrogen production, although there can be some safety issues and cangenerally be more expensive than aluminum.

Experiments were conducted to determine whether the electro-activationof a material, e.g., carbon, can increase hydrogen production. In eachexperiment, a catalyst was used with an aluminum and water mixture. InExperiment 1, non-electro-activated carbon was used as a catalyst. InExperiment 2, unwashed electro-activated carbon was used as a catalyst.In Experiment 3, washed electro-activated carbon was used as a catalyst,where the electro-activated carbon was rinsed with water after theelectro-activation of the carbon.

Experiment 1

In Experiment 1, carbon (i.e., charcoal) was used as a catalyst that wasnot electro-activated. The chamber was cleaned, and approximately 3teaspoons of aluminum powder (having a particle diameter ofapproximately 30 microns) were added to the chamber along withapproximately 7 teaspoons of non-electro-activated charcoal. The chamberwas filled to approximately 60% of the chamber with water so that thecharcoal was slightly below the water line. A heating element was usedto heat the mixture of the catalyst, aluminum powder and water. Thetemperature and hydrogen generation rates are provided in the chartbelow.

TIME TEMP. (degrees (minutes) Fahrenheit) RATE (mL/min) 0 91 0  2:15Visual indication of bubbles  5:00 123 10  6:30 128 80 10:25 140 22012:15 144 180 31:00 157 160 40:00 160 160 50:00 155 140 54:00 161 9073:00 164 110

It was observed that non-electro-activated charcoal did not producesignificant hydrogen generation.

Experiment 2

In Experiment 2, carbon (i.e., charcoal) was used as a catalyst that waselectro-activated at 6 Ampere hours. The chamber was cleaned, andapproximately 2 teaspoons of aluminum powder (having a particle diameterof approximately 30 microns) were added to the chamber along withapproximately 4 teaspoons of unwashed electro-activated charcoal. Thechamber was filled with water and a heating element was used to heat themixture of the catalyst, aluminum powder and water. The temperature andhydrogen generation rates are provided in the chart below.

TIME TEMP RATE TIME TEMP RATE (mins.) (° F.) (mL/min) (mins.) (° F.)(mL/min) 0 76 0 27:20 154 2500  8:50 146 115 42:00 104  9:52 153 31043:30 111 10:52 157 320 44:20 117 400 12:07 162 260 44:45 121 800 13:50164 190 45:00 123 1300 16:30 164 125 45:15 125 1300 19:30 166 110 15:32126 1200 22:15 160 800 45:58 130 700 22:37 159 500 46:52 135 360 23:04159 700 48:26 141 210 24:12 158 1200 50:41 143 125

At T=17:00, approximately 40 mL of hot water was added to the chamber.At T=21:00, approximately 1.5 teaspoons of aluminum powder was added tothe chamber. At T=24:12, the heating element was turned off. A hydrogengeneration rate of approximately 2.5 liters per minute was observed atT=27:20 at a temperature of approximately 154 degrees Fahrenheit. AtT=28:00, the chamber was cooled, and the hydrogen generation ratedecreased as the temperature decreased. At T=40:00, approximately 2teaspoons of aluminum powder and approximately 2 teaspoons ofelectro-activated carbon were added to the chamber, and the heatingelement was turned on. At T=50:41, the heating element was turned off,and the temperature of the chamber started to drop.

In Experiment 2, it was observed that a hydrogen generation rate ofapproximately 2.5 liters per minute can be generated at a temperature ofapproximately 154 degrees Fahrenheit. It can be expected that a hydrogencell having a similar amount of aluminum powder and catalyst couldgenerate hydrogen at a rate of more than approximately 3 liters perminute at hydrogen cell temperature ranges of approximately 160 degreesFahrenheit. The use of un-washed electro-activated carbon can increasethe hydrogen production rate by approximately a factor of 10. Incomparison, Experiment 2 generated hydrogen at a rate of approximately2.5 liters per minute, and Experiment 1 generated hydrogen at a rate ofapproximately 0.22 liters per minute where a non-electro-activatedcatalyst was used.

Experiment 3

In Experiment 3, carbon (i.e., charcoal) was used as a catalyst that waselectro-activated at 6 Ampere hours. After it was electro-activated, thecharcoal was washed with running water for approximately 30 minutes. Thechamber was cleaned, and approximately 2 teaspoons of aluminum powder(having a particle diameter of approximately 30 microns) were added tothe chamber along with approximately 2 teaspoons of washedelectro-activated charcoal. The chamber was filled with water and aheating element was used to heat the mixture of the catalyst, aluminumpowder and water. The temperature and hydrogen generation rates areprovided in the chart below.

TIME TEMP RATE TIME TEMP RATE (mins.) (° F.) (mL/min) (mins.) (° F.)(mL/min) 0 78 0  6:55 152 1000 0:30 99  7:14 153 500 1:20 107 300  7:52153 500 1:55 111 500  9:08 154 250 2:30 120 500 12:55 158 3:50 136 25014:00 153 4:00 150 15:00 143 6:36 152 450 16:00 134

At T=4:00, the heating element was turned off. At T=5:00, approximately0.5 teaspoons of aluminum powder was added. At T=9:08, it was observedthat the chamber was running low on aluminum fuel. At T=12:55, a coolingelement was introduced to the mixture of water, aluminum powder andcatalyst, and a temperature drop was noted from T=12:55 to T=16:00.

In Experiment 3, it was observed that hydrogen can be generated at arate of approximately 1 liter per minute using washed electro-activatedcarbon (i.e., charcoal) for a catalyst. By comparison, in Experiment 2,hydrogen was generated at a rate of approximately 2.5 liters per minuteusing unwashed electro-activated carbon as a catalyst.

Electro-Activation

In exemplary embodiments of the present disclosure, carbon (in the formof 16-mesh carbon granules) was electro-activated, and samples wereremoved at different lengths of time to determine how many Ampere hoursproduced a catalyst with a high rate of hydrogen production. Carbon wasplaced in a chamber and electro-activated at 2 Amperes. Sample 1 wasremoved after an electro-activation time of 1 minute, Sample 2 wasremoved after an electro-activation time of 45 minutes, Sample 3 wasremoved after an electro-activation time of 3 hours, Sample 4 wasremoved after an electro-activation time of 15 hours, and Sample 5 wasremoved after an electro-activation time of 16 hours.

Approximately ⅛ of a teaspoon of each catalyst material (i.e., Samples1-5) was placed in individual chambers having approximately 20 mL ofwater each. Water used in this experiment was filtered tap water.Approximately ⅛ of a teaspoon of aluminum powder was provided in eachchamber. The mixture of the aluminum, water and catalyst in each chamberwas then brought to a temperature ranging from approximately 160 degreesFahrenheit to approximately 200 degrees Fahrenheit. All the chamberswere approximately at the same temperature at any given time, as all thechambers were provided on one multi-chamber container vessel that wasplaced on a heating device. Hydrogen generation rates were observed, andall five samples generated hydrogen. It was found that Sample 3 produceshydrogen at a higher rate than the other samples, and it was found thatadditional electro-activation time to that of Sample 3 had a smalleffect in the hydrogen production rate. In this exemplary embodiment,Sample 3 was electro-activated at 6 Ampere hours (i.e., 3 hours at 2Amperes).

The tests described above provide that the catalytic carbon preparedaccording to the exemplary embodiments of the present disclosure can bean excellent material for use in splitting water to produce hydrogen athigh rates of production. Further, the tests showed that after carbon iselectro-activated according to the exemplary embodiments of the presentdisclosure, an enhanced effect as a catalyst can be semi-permanent,lasting up to several weeks and even months. The catalytic carbon isreusable (i.e., the catalytic effect of the electro-activation ispreserved). The catalytic carbon can be stored and used months later,having the same effect as a fresh catalyst (i.e., catalytic carbon) withwater and aluminum as fuels. Further, the catalytic carbon can be usedseveral times over with water and aluminum being the only consumed fuelsin the exemplary catalytic reactions described in the presentdisclosure.

In some exemplary embodiments, it was shown that catalytic carbon, intrace amounts, can be left behind in the vessel/hydrogen cell even afterwashing/cleaning of the vessel/hydrogen cell. Accordingly, in someexperiments where electro-activated carbon was not used, but was usedpreviously in the same vessel, some hydrogen production was noted whenthere should have been close to none. Accordingly, using the same vesselover and over can provide certain advantages when using catalytic carbonto produce hydrogen.

In some exemplary embodiments, it was found that “wet” electro-activatedcarbon (i.e., electro-activated carbon still wet from the water in theelectro-activation process) produced hydrogen generation rates that wereapproximately 5-10% higher than the hydrogen generation rates producedwhen the catalytic carbon was dried. This can be because the wetcatalytic carbon can have less surface-modification history. Washing thecatalytic carbon can involve some minor surface changes at the surfaceof the carbon. Drying the catalytic carbon can also allow for possiblesurface abrasion when the carbon particles are moved, shifted or poured.Catalytic carbon can be a surface-reacting heterogeneous catalyst. Insome exemplary embodiments, it has been shown that the carbon surfaceimmediately following the electro-activation process can be optimum forhydrogen generation, and any surface treatment or damage followingelectro-activation (e.g., washing or drying) can result inslightly-reduced catalytic effectiveness when the catalytic carbon isused to split water and produce hydrogen in accordance with thecatalytic reactions described in the present disclosure.

Carbon can exhibit good tendencies for electro-activation and use as acatalyst in hydrogen production with water. Carbon is an element thatcan have electronegativity similar to hydrogen and can form a polar bondwith hydrogen. Carbon can form a polar oxide surface layer in water, andcarbon can be pseudo-soluble in water in the form of a colloidalsuspension of carbon particles in water.

The exemplary embodiments of the present disclosure can use water andaluminum as fuel for the exemplary chemical reactions described herein.The potential use of water from various sources and lower cost, lowerpurity aluminum can provide for alternative low-cost sources that can beused to provide fuels for the catalytic reactions according to theexemplary embodiments of the methods and systems of the presentdisclosure.

Aluminum, an element that can be used as a fuel in the exemplaryembodiments of the present disclosure for producing hydrogen, can reactwith acids and bases. Like other active metals, aluminum can dissolve instrong acids to evolve hydrogen gas. The catalytic carbon described inthe present disclosure can be used in pH-neutral liquid based on itsstrong catalytic efficiency (i.e., high reaction rate). This can meanthat the water can be neither a strong acid nor a strong alkalineliquid, which can provide a very safe and environmentally-friendlymixture.

In some exemplary embodiments of the present disclosure, aluminumshavings can be used in the chemical reactions described herein insteadof aluminum powder. The use of electro-activated carbon with aluminumshavings and other non-powder forms of aluminum have been shown tosuccessfully produce hydrogen in a laboratory.

For a given mass of aluminum in the reaction, the hydrogen productionrate can be approximately proportional to the surface area of thealuminum metal. The aluminum used in some of the exemplary embodimentsof the present disclosure can be powdered aluminum. The highersurface-to-volume ratio of powdered aluminum can make it suitable for ahigher rate of hydrogen production for a given amount of aluminum. Morecoarse fuel, which can be in the form of aluminum pellets, aluminumshavings, aluminum granules or aluminum sheets, can also be used. Suchcoarse fuel can provide for hydrogen production which can be at a lowerrate (for a given amount of aluminum) than provided by powdered aluminumin some of the exemplary embodiments of the present disclosure. Use ofpure aluminum may not be required, which can make possible the use oflower cost, lower purity aluminum in the hydrogen production accordingto the exemplary embodiments of the present disclosure.

The size of the aluminum used can be a design variable for a particularapplication. For example, the particle size of the aluminum can bechosen to achieve a desired hydrogen production rate for a design thathas a defined geometry and operating temperature. In general, for agiven amount of aluminum, as the particle size of the aluminumdecreases, the reaction rate of the chemical reaction described in thepresent disclosure goes up at any given temperature. Also, the reactionrate increases as the temperature increases.

In some exemplary embodiments of the present disclosure, it was foundthat hydrogen is generated in the reaction described above without theuse of aluminum (i.e., just using electro-activated carbon and water),but that adding certain fuels, such as aluminum, increased theproduction of hydrogen. It was also found that other fuels besidesaluminum can be used. It was also found that during the catalyticreaction to generate hydrogen, when aluminum powder is being used,hydrogen generation can increase when the aluminum powder is mixed orstirred during the reaction. A mechanical action can be provided toremove aluminum oxide and expose bare aluminum. The chemical reactionsdescribed in Equations 1 and 2 produce hydrogen at higher rates whenbare aluminum is used, and produce less hydrogen when using aluminumwith an oxidized surface. In some exemplary embodiments of the presentdisclosure, by using a blender or other device to chop/burnish aluminumshavings and pellets, hydrogen production rates increased by factors ofapproximately two to ten, depending on the intensity of the mechanicalor electro-mechanical action (i.e., chopping, burnishing and/or mixingof the aluminum). The factors can be dependent on the burnishing timeand the time delay between burnishing and hydrogen production. This timedelay can result in the formation of a film when the bare aluminumsurface is exposed to air or water, particularly at temperatures aboveroom temperature. Burnishing of the aluminum can remove the aluminumoxide from the surface of the aluminum, providing a fresh aluminumsurface for the hydrogen-producing chemical reactions described inEquations 1 and 2 in the present disclosure.

There may be other methods/devices for removing the oxide/hydroxide andproviding a substantially bare aluminum surface for thehydrogen-producing reactions described in the present disclosure, andthe present disclosure is not limited to any such method/device. Forexample, in addition or as a substitute to mechanical burnishing,treatments of the aluminum surface may also be thermal, optical orchemical.

In some exemplary embodiments, aluminum shavings can be reacted with anaqueous solution of sodium hydroxide (NaOH), which can speed thechemical reactions described in the present disclosure reaction by afactor of 10 or more. This process can be a straightforward chemicalreaction in which the sodium hydroxide undergoes a chemical change,i.e., the sodium hydroxide is transformed and consumed in the process.

The combination of the aluminum and sodium hydroxide can be combinedwith the catalytic reactions described in the present disclosure, i.e.,Equations (1) and (2). For example, in some exemplary embodiments,hydrogen can be generated according to the following chemical reaction:

2Al+2[NaOH]+6[H₂O]+C=>C+2[NaAl(OH)₄]+3H₂   Equation (4)

where the Al is aluminum, H is hydrogen, O is oxygen, NaAl(OH)₄ issodium tetrahydroxyaluminate, and C is electro-activated carbon (orcatalytic carbon). In this exemplary reaction, water, aluminum andsodium hydroxide can be fuels that can be consumed, and the catalyticcarbon C can be a catalyst.

In some of these exemplary embodiments, the reaction can begin slowlywhich can be due to the layer of aluminum oxide on the surface of thealuminum. In these exemplary embodiments, once the layer of aluminumoxide is pierced during the reaction, the reaction can then speed up. Insome exemplary embodiments, the reaction sped up after 1 to 3 minutes,at temperatures ranging from standard room temperature up to 180 degreesFahrenheit. The speed of the reaction can depend on various factors,such as temperature, and the amount of aluminum, water and/or sodiumtetrahydroxyaluminate. Other solutions and/or elements may be used tospeed up the catalytic reaction, such as salt (NaCl) and/or otherelectrolytes.

According to the exemplary embodiments of the present disclosure, watercan be used from various different sources. The use of pure water maynot be required. Therefore, it may not be necessary to use distilledwater or de-ionized water for the production of hydrogen, which can bemore expensive than, e.g., tap water or sea water. In exemplaryembodiments of the present disclosure, various water sources were usedin the exemplary chemical reactions, including tap water, dirty water,high-calcium water, salt water, sea water, alkaline water, and acidicwater. In these experiments, it was found that all these various watersamples worked well in the chemical reactions of the exemplaryembodiments of the present disclosure for hydrogen production. In someexemplary embodiments of the present disclosure, it was found that someforms of water, including salt water and alkaline water, can provide aslightly higher rate of hydrogen production than more pure forms ofwater, such as deionized water or distilled water. This can be becausesalt water and alkaline water can have additives that can tend to ionizethe water, which can make it more chemically active and/or more mobilein an aqueous solution. This can be because electrostatic fields,created by the polar oxides, form forces that move the chemicals in theliquid.

The use of water from various sources can provide, e.g., more designlatitude and freedom to a user in selection of construction materialsfor a hydrogen cell, water and water ingredients to minimize corrosionof the materials used in the construction of a hydrogen cell andassociated parts according to the exemplary embodiments of the presentdisclosure. Such use of water from various sources can provide forsignificant cost reduction by, e.g., making it possible to use a widerrange of materials.

The use of salt water and/or sea water for hydrogen production accordingto the exemplary embodiments of the present disclosure can make itsuitable for marine applications, as well as providing an energy sourcefor coastal areas. The exemplary embodiments of the present disclosurecan provide hydrogen production in all parts of the world and near anyseashore, including remote islands. Accordingly, many island nations canuse the exemplary embodiments of the present disclosure to, e.g.,decrease fuel costs and reduce or eliminate the need for tanker-shipimport of fossil fuels.

The exemplary embodiments of the present disclosure can produceby-products that are fully recoverable using existing commercial methodsfor producing aluminum metal. The by-products from the hydrogenproduction methods and systems according to the exemplary embodiments ofthe present disclosure can be desirable because they are pure, and cancontain no contaminants including bauxite, gibbsite, boehmite, goethite,hematite, kaolinite, and TiO₂. The large volume of by-products of theexemplary embodiments of the present disclosure can be Al(OH)₃ andAl₂O₃, which can be recycled to produce more aluminum metal. Recyclingof aluminum hydroxide and aluminum oxide makes the exemplary embodimentsof the present disclosure economically viable for large volume hydrogenproduction.

Aluminum refining from aluminum-bearing bauxite ore can use the Bayerprocess chemistry which can form a hydrate which can be essentially thesame as the reaction product in the aluminum-water reactions describedabove according to the exemplary embodiments of the present disclosure.The hydrate can be calcined to remove the water to form alumina. Thealumina can then be electrolytically reduced into metallic aluminum atabout 900 degrees Celsius using the Hall-Heroult Process, producingaluminum metal with 99.7% purity.

FIG. 2 illustrates a system for the production of hydrogen according toexemplary embodiments of the present disclosure. A hydrogen cell 200 canbe provided where a heating subunit 202 can be provided having a heatingelement 208 within. The heating element 208 can be of various types,such as an electrical heater, a glow plug, a heat-exchanger coil withhot water running through it, but is not limited to such. A powersupply, such as, e.g., a wire 204, can be provided to power the heatingsubunit 202 and/or heating element 208. If hot water is used to provideheat to the heating element 208, 204 can represent the input/output ofthe hot water. In other embodiments, the heating element may runindependently on a battery and/or may be within the hydrogen cell 200.Within the hydrogen cell 200, aluminum and water can be provided as,e.g., fuels, and catalytic carbon can be provided as, e.g., a catalyst.The catalytic carbon, water and aluminum can be in contact with eachother in a mixture in the hydrogen cell 200 as needed to, e.g., heat themixture of the catalytic carbon, water and aluminum.

In an exemplary embodiment of the present disclosure, one part catalyticcarbon can be provided with one part aluminum, which can be in the formof aluminum powder, flakes or granules, with approximately three partswater, in the hydrogen cell 200. Various ratios of the catalytic carbon,aluminum and water can be used, and the present disclosure is notlimited to any particular ratio. In some exemplary embodiments, 1-3tablespoons of 30-micron aluminum powder can be used as the fuel.

The mixture of the catalytic carbon, water and aluminum can then beheated using the heating element 208 to a temperature of approximately140 degrees Fahrenheit to approximately 190 degrees Fahrenheit. Thepresent disclosure is not limited to any temperature ranges, and varioustemperatures may be used according to different embodiments of thepresent disclosure. In some exemplary embodiments, the mixture can beheated to approximately 180 degrees Fahrenheit, which can preventexcessive loss of water due to vaporization or boiling. Waterevaporation (and heat loss, or cooling) can be controlled and limited byoperating the hydrogen cell in a temperature range of approximately 160degrees Fahrenheit to approximately 180 degrees Fahrenheit that is belowthe boiling temperature of water (i.e., 212 degrees Fahrenheit at sealevel). From the equations described above, the reaction produceshydrogen and aluminum hydroxide, and the hydrogen can be collected athydrogen output 206. The aluminum hydroxide can be collected within thehydrogen cell 200 or outside of the hydrogen cell 200, using appropriatestructures and elements.

FIG. 3 illustrates a system for the production of hydrogen according toexemplary embodiments of the present disclosure. The system of theexemplary embodiment of FIG. 3 is similar to the system in the exemplaryembodiment of FIG. 2, which can have a hydrogen cell 300, a wire 304providing electrical power to a heating element 308 within a heatingsubunit 302, where catalytic carbon is used as a catalyst and aluminumand water are used as fuels. The heating element 308 heats the mixtureof catalytic carbon, aluminum and water to produce hydrogen and aluminumhydroxide, and the hydrogen can be collected at hydrogen output 306. Inaddition, the exemplary embodiment of FIG. 3 can have a cooling subunit310. For example, the cooling subunit can have within a cooling coilhaving a cold water input 312 and a water output 314. The cooling coilcan be in contact with the mixture of water, aluminum and catalyticcarbon. The cooling can slow down the reaction process, therebydecreasing the rate and volume of hydrogen generation. Such a system canbe used to produce hydrogen on demand, where appropriate instruments andtools can be used to produce the temperatures needed to increase andslow down the rate and volume of hydrogen generation.

In an experiment of the system of FIG. 3 according to the exemplaryembodiments of the present disclosure, the hydrogen cell 300 was filledwith approximately one pint of tap water, along with approximately 4 mLof aluminum powder (having a particle size of 3 microns) andapproximately 4 mL of electro-activated carbon. The heating subunit 302heated the mixture of water, aluminum powder and electro-activatedcarbon at approximately 2-3 degrees Fahrenheit per minute. The hydrogencell 300 was heated for approximately 30 minutes, and the heatingsubunit was then turned off. The temperature of the hydrogen cell 300 atthis time was approximately 190 degrees Fahrenheit. As shown in thegraph below, the rate R of hydrogen production at time t=20 minutes wasapproximately 300 mL/min, and soon after peaked at approximately 490mL/min.

When the hydrogen producing reaction began, the exothermic nature of thereaction kept the temperature at approximately 190 degrees Fahrenheituntil the fuel (i.e., aluminum powder) was mostly consumed atapproximately t=50 minutes into the experiment. The total volume ofhydrogen produced in the experiment was approximately 4 liters. Atapproximately t=25 minutes, cold water was provided into the coolingsubunit 310 (i.e., cooling coil) through cold water input 312, and thecooling rate was measured to be approximately 2-3 degrees Fahrenheit perminute.

In a second experiment, using the same electro-activated carbon from theprevious experiment, approximately 12 mL of aluminum powder was providedin the hydrogen cell 300. The peak hydrogen production rate was measuredto be approximately 2.5 liters per minute at approximately t=12 minutes.After approximately 25 minutes, the total volume of hydrogen gasproduced was approximately 20 liters. After the experiments, nocorrosion was visible on the heating subunit 302, cooling subunit 310 orhydrogen cell 300.

The exemplary system of FIG. 3 can provide hydrogen “on-demand.” Heatingup the hydrogen cell 300 can increase the temperature and increase thehydrogen production. Factors (i.e., control parameters) that can beconsidered when generating hydrogen and increasing the hydrogenproduction can be the amount of water, amount of electro-activatedcarbon, amount and type of aluminum, the manner and rate ofoxide/hydroxide removal from the aluminum surface, and the temperature.

Cooling the hydrogen cell (e.g., by providing cold water into thehydrogen cell) can reduce the temperature, thereby reducing the hydrogenproduction. When providing hydrogen on-demand, various factors (i.e.,control parameters) can be considered in order to decrease the rate ofhydrogen production. For example, if the amount of water is reduced,such as by removing the water from the hydrogen cell, this can stop theproduction of hydrogen. Reducing the amount of electro-activated carboncan also reduce the amount of hydrogen production, although it can bedifficult to completely remove all the electro-activated carbon, astrace amounts may still be in the hydrogen cell. Reducing thetemperature in the hydrogen cell can also reduce the hydrogenproduction. For example, reducing the temperature of the hydrogen cellby approximately 18 to 20 degrees Fahrenheit can reduce the hydrogenproduction rate in the hydrogen cell by a factor of approximately 2.Reducing the temperature of the hydrogen cell by approximately another18 to approximately 20 degrees Fahrenheit can again reduce the hydrogenproduction in the hydrogen cell by a factor of approximately 2, and soon. This can be done by using a cooling subunit 310, or otherdevices/methods to reduce the temperature of the hydrogen cell 300.

Aluminum can be a more efficient fuel in the chemical reaction withwater and electro-activated carbon when burnished (i.e., usingmechanical scrubbing to remove aluminum oxide and/or aluminum hydroxidefilms covering the surface). If a mechanical action of burnishing orstirring or any other method is used to remove the aluminum oxide and/oraluminum hydroxide on the surface of the aluminum, then stopping thatprocess or reducing that process in the hydrogen cell can cause aluminumoxide to form on the surface of the aluminum, which can reduce thehydrogen production. Also, removing the aluminum from the hydrogen cellor from the reaction can also stop the hydrogen production in thehydrogen cell. These control parameters can each be used alone or incombination with one another to slow or stop the hydrogen production,thereby providing hydrogen on-demand.

It may be possible to control the maximum hydrogen production rate,e.g., in a vehicle, by using the vehicle's thermostat that regulatesengine/radiator water temperature (typically about 195 to 200 degreesFahrenheit for a car) to achieve a regulated hydrogen cell temperature.At that temperature, a catalyst can be blended to achieve a desiredhydrogen maximum flow rate. This can make it unnecessary to measure andcontrol the hydrogen cell temperature unless the exothermic nature ofthe reaction makes it necessary to do so. If, due to exothermictemperature rise, the hydrogen cell temperature exceeds theengine/radiator water temperature in an automobile (typically 195 to 200degrees Fahrenheit), the water in the vehicle's radiator system can thenbegin to cool the hydrogen cell, thereby providing temperatureregulation. In this exemplary design concept, cooling from a differentwater (or other coolant, including but not limited to freon, ethyleneglycol and/or propylene glycol) source can also be used to slow down thechemical reaction when the engine is stopped. Other hydrogen shutdownmethods can be water starvation and/or aluminum starvation.

The systems described in the present disclosure can be combined withexisting systems for producing hydrogen in some exemplary embodiments ofthe present disclosure. For example, a hybrid system can be provided forproducing hydrogen that combines the system(s) of the present disclosurewith an electrolysis system. An electrolysis system can producesignificant heat, and that heat can be used to start or to keep up thereactions described in the present disclosure. For example, the heatfrom an electrolysis system can start or keep up the reaction ofEquation 1, where water, aluminum and electro-activated carbon areheated to produce hydrogen. The hydrogen produced from either one orboth systems can then be used for the particular purpose. This canprovide a method and system where pH-neutral chemistry can be used,which is different from the prior art methods and systems used forgenerating hydrogen using electrolysis.

There can be several advantages for using a hybrid system. A singlechamber can provide for electro-activation of the carbon, as well asprovide for hydrogen generation. Accordingly, the carbon cancontinuously be converted to electro-activated carbon and then producehydrogen. Another advantage can be that more hydrogen can be producedper unit energy input than if electrolysis alone were used, and thepower input required for electrolysis can be used to heat the catalyticreactions described in Equations 1 and 2 to a desired operatingtemperature. Further, the electrolysis chemistry can aid in oxidizingthe aluminum in the catalytic reactions described in Equations 1 and 2to tie up OH chemical groups when the water is split into H and OHgroups.

In some exemplary embodiments, a hybrid system can use electrolysis andcatalytic carbon in combination to produce hydrogen. Often, when usingelectro-activated carbon with a fuel, such as aluminum, aluminum oxideand aluminum hydroxide can be formed in the form of large solids. Thesesolids can be large, and can be difficult to remove during operation ofthe cell as well as during maintenance of the cell. If a low currentelectrolysis is used in the liquid composition containing theelectro-activated carbon and aluminum, then formation of these largesolids can be prevented, such that only very small grains of aluminumoxide and aluminum hydroxide are formed. Another advantage of providingelectrolysis to the cell can be that the energy deposited in the liquidcan be a source of heat. Heat can be used for the catalytic carbonreaction to produce hydrogen at a higher rate, such that the hydrogenproduction rate can double with every increase in temperature ofapproximately 18 to approximately 20 degrees Fahrenheit. Various othercombinations of hybrid systems are contemplated by the presentdisclosure and are not limited to the above.

In exemplary embodiments of the present disclosure, experiments were runto test the purity of the hydrogen produced based on the chemicalreaction of Equation 1. The electro-activated carbon in this experimentwas electro-activated at 6 Ampere hours. Approximately 400 mL ofhigh-purity HPLC grade water was provided in a chamber of a hydrogencell and heated to approximately 170 degrees Fahrenheit. Then,approximately 12 grams of the electro-activated carbon and approximately18 grams of aluminum powder were added into the chamber of the hydrogencell. The reaction achieved a maximum hydrogen generation rate ofapproximately 200 mL/min. It was determined through measurementinstrumentation that the hydrogen produced by this reaction wasapproximately 93% pure. The hydrogen production began with air in thechamber of the hydrogen cell and in the tubes leading to the measurementinstrumentation for the testing of the hydrogen purity. The remaining 7%can be air which can contain water vapor, and the amount of the watervapor can depend on the temperature of the hydrogen cell during thereaction. In this configuration, using the reactions described inEquation 1, the hydrogen automatically separates from the catalyticcarbon, water and aluminum, and there was no need for a phase separatorin the measurement for the hydrogen purity.

FIG. 4 illustrates a system for providing hydrogen as a fuel to avehicle according to exemplary embodiments of the present disclosure.The system can comprise of two primary vessels, a bubbler 400 and ahydrogen cell 406. The hydrogen cell 406 can be connected to the bubbler400 by a tube 402 through which hydrogen bubbles can rise from thehydrogen cell 406 to the bubbler 400. The hydrogen cell 406 can beheated with a glow plug 405, or some other type of heatingelement/device. The glow plug 405 or other heating element can beelectronically controlled to maintain a hydrogen cell temperature, e.g.,approximately 180 degrees Fahrenheit, using a thermistor temperaturesensor 407 or other similar temperature sensing and controlling device.Water, aluminum (e.g., aluminum powder) and catalytic carbon can beplaced in the hydrogen cell 406.

A water level 401 can be maintained such that the hydrogen cell 406 canbe full of the mixture of the water, aluminum powder and catalyticcarbon, and the bubbler 400 can be partially filled with the mixture upto the water level 401. A mechanical action can be added into thehydrogen cell in order to burnish/stir/mix the aluminum if desired toremove any aluminum oxide from the aluminum surface in order to generatemore hydrogen, if needed. Once heated, hydrogen bubbles will rise to thechamber area 403 in the bubbler 400 using gravity flow, and the hydrogengas can be provided to an air-intake manifold of the vehicle enginethrough outlet 404.

In an experiment using the exemplary system of FIG. 4, the hydrogen cell406 and bubbler 400 were attached to an engine of a test vehicle usingbrackets to hold the hydrogen cell 406 and bubbler 400, and the outlet404 was connected to an air-intake manifold of the engine of the testvehicle. No oxygen sensor adjustments or other engine modifications wereimplemented. Under normal driving conditions (i.e., no hydrogen), thetest vehicle achieved approximately 26-28 miles per gallon duringhighway driving using regular unleaded fuel.

The first (non-optimized) experimental operation of the test vehicleshowed that providing hydrogen produced a dramatic increase in miles pergallon. At t=0 minutes, the hydrogen cell 406 was charged withapproximately 2 teaspoons of aluminum powder, approximately 2 teaspoonsof catalytic carbon, and water. The heating element (i.e., glow plug)was turned on. Initial heating and hydrogen flow took approximately 5minutes. Hydrogen was formed in the chamber 403 of the bubbler 400. Att=5 minutes, the test vehicle was started with hydrogen flowing from theoutlet 404 to the vehicle engine. The electronic fuel injection (EFI)computer automatically began operation in the open loop mode (i.e.,normal engine start-up mode, with no feedback signals from the oxygensensors) to closed loop (i.e., normal mode after the engine warms up,using feedback signals from the oxygen sensors). During this warm-upperiod, hydrogen was flowing from the hydrogen system output 404 to theair-intake manifold of the engine of the test vehicle. The test vehiclewas brought to a speed of approximately 55 miles per hour on a highway,and the hydrogen flow rate was estimated to be approximately 0.3 litersper minute. The vehicle was obtaining approximately 37 miles per gallonas measured by a scan gauge adjusted to measure real-time mileage inunits of miles per gallon.

At t=10 minutes, the hydrogen flow rate was noted to be decreasing withtime. The test vehicle was getting approximately 35.7 miles per gallon.The solenoid valve (provided in the plumbing between the outlet 404 tothe engine of the vehicle) was switched so that hydrogen was vented tothe air (not piped to engine). The miles per gallon droppedapproximately 6.7%, from approximately 35.7 miles per gallon toapproximately 33.3 miles per gallon.

The test vehicle demonstrated a 32% increase in miles per gallon duringthe first non-optimized experimental run. In several subsequent testruns with some refinements (i.e., higher hydrogen flow rates), thevehicle demonstrated up to a 40% increase in miles per gallon.

Conventional methods of producing hydrogen (e.g., electrolysis,thermo-forming, etc.) can produce hydrogen at low rates when measured inunits of volume per minute, or liters per minute (LPM) per gram ofmaterial per joule of required energy, or LPM/gm per joule. Using thisexemplary benchmark for production rate evaluation leads to theconclusion that electrolysis and thermo-reforming are poor performerssimply because of the high energy (measured in joules) required to drivethe processes.

In the exemplary embodiments of the present disclosure, hydrogenproduction rates can be much higher than that of electrolysis orthermo-reforming processes. These exemplary embodiments can use externalheat to start the chemical reaction described above, which can generallybe in the temperature range of approximately 150 degrees Fahrenheit toapproximately 190 degrees Fahrenheit, but are not limited to thistemperature range. Generally, the reaction temperature can be as low asstandard room temperature, and even lower, although the hydrogengeneration rate can decrease by approximately 50% for everyapproximately 18-20 degrees Fahrenheit reduction in operatingtemperature. The reaction temperature can be as high as the boilingtemperature of water, and even higher in a steam environment wherehigher flow rates are required. The exemplary embodiments of the presentdisclosure are not limited to a particular temperature range.

Once started, as the catalytic reactions described in the presentdisclosure are fundamentally exothermic, the reactions can provideenough heat to sustain the reactions if the hydrogen cell thermodynamicequilibrium is designed to occur at the desired operating temperature.Thermodynamic-equilibrium operating conditions can be achieved when theamount of energy (heat) leaving the system is the same as the amount ofenergy (heat) entering the system (primarily because of the heat beinggenerated by the exothermic reaction). Under these experimentalconditions, the system temperature can remain constant, andexternally-supplied energy may not be required for heating or cooling.Under different (non-thermal equilibrium) operating conditions, the onlyexternal energy required may be for cooling, if needed to limit thehydrogen production rate to, e.g., a desired target value, and/or limitthe temperature of the cell to prevent boiling or excessive loss ofwater vapor.

In exemplary embodiments of the present disclosure, several experimentalruns were carried out in which hydrogen peak production rates ofapproximately 400 mL/minute to approximately 4 liters/minute wereobtained in a cell, where in each cell tap water was provided withapproximately 10 grams to approximately 40 grams of powdered aluminum,and approximately 2 teaspoons of catalytic carbon that had beenelectro-activated for approximately 6 Ampere hours. These experimentalcells had reaction-chamber volumes ranging from approximately 100 mL toapproximately 1 liter. High rates of hydrogen production weredemonstrated in the experimental runs (e.g., approximately 400 mL/minuteto approximately 4 liters/minute) at temperatures ranging fromapproximately 160 degrees Fahrenheit to approximately 190 degreesFahrenheit. Higher rates can be provided according to the exemplaryembodiments of the present disclosure by, e.g., using larger cells, inwhich more catalytic carbon, aluminum and water can be provided. It wasdemonstrated that controlled, sustained production of hydrogen can beachieved by providing water, aluminum and catalytic carbon to ahydrogen-production cell.

Many other applications for hydrogen production are contemplated by thepresent disclosure along with providing fuels for land and marinevessels, as well as for power generation (e.g., power plants). As shownin FIG. 5, a boiler system can be provided according to exemplaryembodiments of the present disclosure, to provide heat for a buildingstructure, such as a home or commercial building. As shown in theexemplary boiler system of FIG. 5, a hydrogen cell 508 can be provided,in which water, aluminum and catalytic carbon can be provided to producehydrogen gas. The hydrogen gas, though gravity/buoyancy flow, willproceed in an upwards direction 510 to a boiler system 500 (oralternatively, can be directed to the boiler system 500 throughappropriate tubing/piping in another exemplary design).

Hydrogen bubbles 512 will proceed in an upwards direction to a waterlevel 511 in the boiler system 500. A water inlet 507 (which can be roomtemperature or hot water) and a water outlet 509 can be provided in theboiler system 500. Air can be injected in the water or close to thesurface of the water level 511 where the hydrogen bubbles 512 appear by,e.g., a hose, pipe, air compressor, valve, air pressure regulator orother such type of device. An igniter 506 can be provided to ignite thecombustible mixture of hydrogen and air, to provide a flame 502 withinthe boiler system 500. The heat provided by the flame in the boilersystem 500 can be supplied to a heating element, such as fins or otherheat-radiating elements for use as a heater, or the water can be heatedwithout heat radiating elements because of the direct flame-to-watercontact.

In another exemplary embodiment of the system of FIG. 5, a boiler systemcan be operated at a pressure higher than 1 atmosphere, and steam can beprovided through outlet 504 to, e.g., drive turbines to make electricityor provide heat. The operation of a pressurized steam boiler can befitted with pressure regulators and other equipment designed for bothcontrol and safety of operation.

There can be many advantages to a boiler system using hydrogen asdescribed in FIG. 5. For example, since a burner is not required, thereis no burner corrosion or maintenance required. The flame can be indirect contact with the water to heat the water. There is no firebox(furnace) required, and there are no hot gas tubes, fly-ash build up(typically a problem for coal-burning furnace/boiler systems) and nomaintenance of the tubes is required. There is no smokestack required,and the combustion products are merely water/steam. Further, there areno unwanted effluents or emissions and no environmental contamination.

Fossil fuel shortage can be a worldwide problem in the coming years.Fuel transport and storage can also be a major logistics supportproblem, such as for mobile military units. The exemplary embodiments ofthe present disclosure can make it possible to reduce the need fortransport and storage of large volumes of fossil fuel. The availabilityof fuel in the exemplary embodiments of the present disclosure can bebased on the availability of water and aluminum. Dry aluminum is notexplosive under normal conditions, and it can be easy to transport andstore. It may not require special handling or special shelterrequirements because when exposed to natural weather extremes it quicklyforms a protective oxide which can prevent erosion, corrosion or otherdamage to the aluminum. Water can be transported easily in variousforms. Tap water, sea water, salt water and/or any type of water may beused as a fuel in the exemplary embodiments of the present disclosure.

There are only a few materials that can produce abundant hydrogen andthese can include hydrocarbons and water. Of these materials, water canbe a pollution free source of hydrogen. One of the problems that must beaddressed before a new hydrogen economy replaces the current“oil/gas/coal/nuclear” economy, can be finding a safe, environmentallybenign and cost-effective method of generating hydrogen at a desiredrate. The exemplary embodiments of the present disclosure provide safe,cost-effective and environmentally-benign methods and systems ofhydrogen generation.

Carbon, water, aluminum, aluminum oxide and aluminum hydroxide can besome of the safest materials known (e.g., they are commonly used infoods, drugs, cosmetics and other safe to use/handle products). Theexemplary embodiments of the present disclosure provide these elementsin methods and systems that work using a wide range of pH, which caninclude neutral pH values in the range of 6 to 8. The use of neutral pHchemistry can eliminate the threat of acid burns or alkali burns tohuman skin and eyes. Alkali-burn damage to the eyes, due to anaccidental splash, can be a safety hazard when using electrolytes withelectrolysis to produce hydrogen. Electrolysis can fundamentally requirethe use of a strong electrolyte to increase the electrical conductivityof the water, whereas the exemplary embodiments of the presentdisclosure can produce hydrogen chemically, without the use ofelectrolysis and without the requirement for electrolyte additives. Theexemplary embodiments of the present disclosure can be safe andmanageable by simple care.

Some metals other than aluminum can spontaneously produce hydrogen whenthose metals come in contact with water. For example, metals such aspotassium (K) and sodium (Na) can produce hydrogen when they come incontact with water. However, the residual hydroxide product (i.e., KOHin the sodium reaction) can be corrosive, dangerous to handle andpotentially polluting to the environment. These metals can be used aswater-splitting agents through a simple reaction, which can proceedspontaneously once the metal is dropped into water, but these reactionscan be less safe than aluminum and cannot be controlled as easily asaluminum and the reactions described in the exemplary embodiments of thepresent disclosure.

The exemplary embodiments of the methods and systems described hereincan facilitate and/or provide, e.g., fuel for vehicles (trucks, cars,motorcycles, etc.), fuel for marine vessels (boats, submarines, cargoships, etc.), power for power plants which can provide electricity forbuildings, cities, etc., and several other applications where hydrogencan be used as a source of fuel/power. For applications requiring heaterwater or steam, a boiler apparatus can be possible due to the catalyticcarbon reactions described herein that can produce hydrogen under water.There are many fields of use and embodiments contemplated by the presentdisclosure in which hydrogen production, ranging from low to very highflow rates, requiring no tank storage, can be used for various purposes.

Various other considerations can also be addressed in the exemplaryapplications described according to the exemplary embodiments of thepresent disclosure. Various rates of hydrogen generation, along withdifferent volumes of hydrogen generation, can be provided depending onthe field of application. Different factors such as the amount of water,amount of fuel, such as aluminum, and amount of electro-activated carboncan be a factor. One skilled in the art can understand that routineexperimentation based on the exemplary embodiments of the presentdisclosure can provide various rates and volumes of hydrogen generation.Controlling the temperature during these reactions can provide hydrogenon demand, and hydrogen cells can be constructed that can regulate thetemperature of the chamber of the hydrogen cell during the reaction toprovide hydrogen on demand to, e.g., a vehicle.

The foregoing merely illustrates the principles of the disclosure.Various modifications and alterations to the described embodiments willbe apparent to those skilled in the art in view of the teachings herein.It will thus be appreciated that those skilled in the art will be ableto devise numerous systems, arrangements, manufacture and methods which,although not explicitly shown or described herein, embody the principlesof the disclosure and are thus within the spirit and scope of thedisclosure.

What is claimed is:
 1. A method of producing a catalyst for hydrogenproduction, comprising: providing electrical energy to a carbon materialto electro-activate the carbon material; and using the electro-activatedcarbon material to produce hydrogen.
 2. The method of claim 1, whereinthe carbon material is provided in a liquid composition comprisingwater.
 3. The method of claim 2, wherein the liquid composition furthercomprises an electrolyte.
 4. The method of claim 1, wherein theelectrical energy is provided at approximately 6 ampere-hours.
 5. Themethod of claim 1, wherein the carbon material is one or more of purecarbon, solid carbon, crushed carbon, sintered carbon, carboncomposites, charcoal, pressed carbon, carbon blocks, graphite, carbongranules, granulated activated carbon or coal.
 6. A method of producinghydrogen, comprising: combining electro-activated carbon with a liquidcomposition; and generating a chemical reaction between the combinationof electro-activated carbon and the liquid composition to producehydrogen.
 7. The method of claim 6, further comprising: combining theelectro-activated carbon and liquid composition with a fuel; andgenerating a chemical reaction between the combination of theelectro-activated carbon, liquid composition and fuel to producehydrogen.
 8. The method of claim 7, wherein the fuel is one of purealuminum, aluminum powder, aluminum granules or aluminum shavings. 9.The method of claim 7, further comprising: controlling the chemicalreaction of the combination of electro-activated carbon, water and fuelto produce hydrogen on demand.
 10. The method of claim 9, wherein thechemical reaction is controlled by heating the combination to increasethe production of hydrogen, and by cooling the combination to decreasethe production of hydrogen.
 11. The method of claim 10, wherein thecombination is heated to a temperature range between approximately 150degrees Fahrenheit to approximately 190 degrees Fahrenheit.
 12. Themethod of claim 9, wherein the chemical reaction is controlled by addingamounts of one or more of the electro-activated carbon, liquidcomposition and fuel to increase the production of hydrogen, andremoving amounts of one or more of the electro-activated carbon, liquidcomposition and fuel to decrease the production of hydrogen.
 13. Themethod of claim 7, wherein the liquid composition comprises water, tapwater, dirty water, high-calcium water, salt water, sea water, alkalinewater or acidic water.
 14. A system for producing a catalyst forhydrogen production, comprising: an activation cell having a carbonmaterial; and an apparatus configured to provide electrical energy toelectro-activate the carbon material in the activation cell.
 15. Thesystem of claim 14, wherein the carbon material is provided in a liquidcomposition comprising water in the activation cell.
 16. The system ofclaim 15, wherein the liquid composition further comprises anelectrolyte.
 17. The system of claim 14, wherein the apparatus isconfigured to provide electrical energy at approximately 6 ampere-hours.18. The system of claim 14, wherein the carbon material is one or moreof pure carbon, solid carbon, crushed carbon, sintered carbon, carboncomposites, charcoal, pressed carbon, carbon blocks, graphite, carbongranules, granulated activated carbon or coal.
 19. A system forproducing hydrogen, comprising: a vessel having a liquid composition andelectro-activated carbon; and an apparatus for generating a chemicalreaction between the liquid composition and electro-activated carbon toproduce hydrogen.
 20. The system of claim 19, further comprising: a fuelprovided in the vessel with the liquid composition and electro-activatedcarbon; wherein the apparatus generates a chemical reaction between theliquid composition, electro-activated carbon and fuel to producehydrogen.
 21. The system of claim 20, wherein the fuel is one of purealuminum, aluminum powder, aluminum granules or aluminum shavings. 22.The system of claim 20, further comprising: one or more mechanisms tocontrol the chemical reaction between the liquid composition,electro-activated carbon and fuel to produce hydrogen on demand.
 23. Thesystem of claim 22, wherein the one or more mechanisms heat thecombination of the liquid composition, electro-activated carbon and fuelto increase the production of hydrogen, and cool the combination of theliquid composition, electro-activated carbon and fuel to decrease theproduction of hydrogen.
 24. The system of claim 23, wherein the one ormore mechanisms heat the combination of electro-activated carbon, waterand fuel to a temperature range between approximately 150 degreesFahrenheit to approximately 190 degrees Fahrenheit.
 25. The system ofclaim 22, wherein the chemical reaction is controlled by adding amountsof one or more of the electro-activated carbon, liquid composition andfuel to increase the production of hydrogen, and removing amounts of oneor more of the electro-activated carbon, liquid composition and fuel todecrease the production of hydrogen.
 26. The system of claim 19, whereinthe liquid composition comprises water, tap water, dirty water,high-calcium water, salt water, sea water, alkaline water or acidicwater.